Alkyl transfer of alkyl aromatics with group vib metals on mordenite

ABSTRACT

A process for the alkyl transfer of alkyl aromatics including contacting an alkyl aromatic feed material, such as toluene, with a catalyst comprising a Group VIB metal, such as chromium, molybdenum and tungsten deposited on a synthetic mordenite base at a temperature of about 700* to 1,100* F, a pressure of about 0 to 2,000 psig, and a liquid hourly space velocity of about 0.1 to 10, and in the presence of hydrogen introduced at a rate of about 1 to 10 moles hydrogen per mole of hydrocarbon feed. Promoters selected from Group I, Group II, Group IV, and the Rare Earth metals of the Periodic System may be added to the catalyst. Deactivated catalyst may be periodically rejuvenated by discontinuing the introduction of aromatic feed material and purging with hydrogen and the catalyst can be reactivated by calcination in an inert atmosphere such as air. Where toluene is the feed, the alkyl transfer product may be distilled to separate benzene, toluene and xylenes, the toluene may be recycled to the alkyl transfer step, the xylenes may be crystallized to separate para-xylene from the remaining xylenes, the mother liquor from the crystallization step may thereafter be isomerized to readjust the para-xylene content and the product of the isomerization may be recycled to the crystallization zone.

United States Patent Kmecak et al.

[ Oct. 17, 1972 [5 ALKYL TRANSFER OF ALKYL Primary Examiner-Delbert E. Gantz AROMATICS WITH GROUP VIB Assistant Examiner-G. E. Schmitkons METALS ON MORDENITE Attorney-Walter H. Schneider [72] Inventors: Ronald A. Kmecak; Stephen M. v

Kovach, both of Ashland, Ky. [57] ABSTRACT [73] Assignee: Ashland Oil, Inc. A process for the alkyl transfer of alkyl aromatics including contactlng an alkyl aromatic feed material, 1 Filedi 1968 such as toluene, with a catalyst comprising a Group [21] AppL NM 785,177 VIB metal, such as chromium, molybdenum and tungsten deposited on a synthetic mordenlte base at a temperature of about 700 to l,l00 F, a pressure of [52] U.S.Cl. ..260/672 T, 208/58,208/111, about 0 to 2,()QO p ig, and a liquid hourly space 208/217, velocity of about 0.1 to 10, and in the presence of 252/455 Z, 252/462, 260/667, 260/668 A hydrogen introduced at a rate of about 1 to 10 moles 260/674 H hydrogen per mole of hydrocarbon feed. Promoters [51] Int. Cl. .....C07c 3/62, C07c 11/04, Cl0g 23/00, selected m Group I, Group I], Group IV, and the 8 31/14 Rare Earth metals of the Periodic System may be [58] Field of Search ..260/672T added to the catalyst Deactivated catalyst may he periodically rejuvenated by v discontinuing the in- [56] References C'ted troduction of aromatic feed material and purging with UNITED STATES PATENTS hydrogen and the catalyst can be reactivated by calctnation in an inert atmosphere such as air. Where 3,250,728 Miale 611 a] toluene is the feed the transfer product may be Weisz to eparate benzene toluene and xylenes, the 3,442,794 5/1969 i Heme" et a] 308/11 1 toluene may be recycled to the alkyl transfer step, the Mltsche ylenes may be crystallized to separate para xylene 3,464,929 9/1969 Mitsche ..252/4'42 from the remaining xylenes, the mother liquor f 3,476,821 11/1969 Brandenburg the crystallization step may thereafter be isomerized 2,795,629 6/1957 Bede ker "260/668 to readjust the para-xylene content and the product of 3,281,483 10/1966 Benesi et a1. ..260/672 the isomerization may be recycled to the erystahiza 3,562,342 2/1971 Hebert et a1 ..260/668 hon Zone 3,597,491 8/1971 Kovach et a1 ..260/672 11 Claims, 1 Drawing Figure 2 TOLUENE 4 BENZENE 0 44 24 3a 4 22 28 F? j g a z s 5 E a Q g 9 U E 1 U) 5 26 32 36 -XYLENE N18 48 20 FLASH XYL NE ALKYL TRANSFER OF ALKYL AROMATICS WITH GROUP VIB METALS ON MORDENITE BACKGROUND OF THE INVENTION The present invention relates to a process for the catalytic conversion of hydrocarbons and, more particularly, to a process for the catalytic alkyl transfer of alkyl aromatics.

Aromatic hydrocarbons, such as naphthalene, and their alkyl derivatives are important building blocks in the chemical and petrochemical industries. For example, benzene and its derivatives have numerous uses; cyclohexane is utilized in nylon production; naphthalene is utilized in the production of phthalic anhydride for alkyd resins, etc.; para-xylene can be used for the production of terephthalic acid which, in turn, is utilized in the production of synthetic resins, such as dacron, mylar, etc., etc. i

For many years, the primary source of such aromatic hydrocarbons has been coal tar oils obtained by the pyrolysis of coal to produce coke. Such coal tar oils contain principally benzene, toluene, naphthalene, methylnaphthalene and para-xylene. Benzene may be produced from such oils by direct separation, such as distillation techniques, the para-xylene may be separated by crystallization, and the naphthalene fractions by direct separation techniques. Further alkyl derivatives of benzene and naphthalene can be converted to increased volumes of benzene and naphthalene by hydrodealkylation.

More recently, however, the petroleum industry has become a leading source of these aromatic hydrocarbons. The reason for this has been the availability of the catalytic reforming process in which naphthene hydrocarbons are dehydrogenated to produce a reformate rich in aromatics and more efficient processes for separating the aromatics from the reformate.

Some years ago, there was a high demand for toluene which was used in the production of TNT. This led to the building of substantial facilities for its production. However, the advent of nuclear and fusion weaponry and the use of diesel oil-ammonium nitrate explosives has left toluene in substantial over-supply, since the only major uses of toluene are as a solvent, the production of toluene diisocyanates and the production of benzene. This has resulted in extensive efforts to develop methods for converting toluene to benzene. One method of converting toluene to benzene is by the previously mentioned hydrodealkylation.

Dealkylation has the primary disadvantage that methane is a major product. Volume yields of benzene are therefore low and carbon deposition on the catalyst is high. The large amounts of methane, while useful as a fuel, require expensive techniques for the removal of the methane from the circulating hydrogen stream utilized in the hydrodealkylation. In addition, large quantities of hydrogen are consumed in the dealkylation process and hydrogen is often in short supply and expensive to produce. Finally, where catalysts are used in the process, carbon laydown on the catalyst is a serious problem.

A more profitable reaction for changing alkyl aromatics to other aromatic products is an alkyl transfer reaction. An alkyl transfer reaction is a process wherein alkyl groups are caused to be transferred from the nuclear carbon atoms of one aromatic molecule to benzene,

the nuclear carbon atoms of another aromatic molecule. By way of example, an aromatic hydrocarbon molecule containing one nuclear alkyl substituent, such as toluene, may be treated by disproportionation to produce an aromatic hydrocarbon with no alkyl substituents, namely, benzene, and aromatic hydrocarbon molecules with two nuclear alkyl substituents, namely xylenes. Similarly, product ratios may be shifted by transalkylation of xylene and benzene to toluene. Such an alkyl transfer reaction has distinct advantages: methane is not produced, but instead, valuable aromatic hydrocarbons are produced in addition to the desired aromatic hydrocarbon. As a result, there is very little loss of product in alkyl transfer as opposed to hydrodealkylation.

Alkyl transfer may be carried out thermally. However, thermal alkyl transfer. results in demethylation due to cracking and hydrogenation, ultimately resulting in low yields of desired aromatics. On the other hand,

catalytic alkyl transfer has not been highly successful since it requires an active, rugged, acidic catalyst. Typical catalysts are solid oxides, such as silica-alumina, silica-magnesium, etc. These materials, however, arenot active enough to promote disproportionation at high' conversion rates. In addition, as is the case in hydrodealkylation, carbon deposition on the catalyst and its affect on catalyst activity with time is a severe problem.

It is therefore an object of the present invention to vention is to provide an improved process for the disproportionation of alkyl aromatics with a catalyst system resistant to carbon lay-down. A further object of the present invention is to provide an improved process for the catalytic disproportionation of alkyl aromatics utilizing a Group VIB metal on a synthetic mordenite base. A further object of the present invention is to provide an improved process for the disproportionation of alkyl aromatics utilizing critical conditions of temperature and pressure which produce maximum disproportionation and conversion of one aromatic to another. Still another object of the present invention is to provide an improved process for the conversion of toluene to benzene and xylenes and conversion of metaand ortho-xylenes to additional paraxylene. These and other objects and advantages of the present invention will be apparent from the following detailed description.

SUMMARY OF THE INVENTION Briefly, in accordance with the present invention, alkyl transfer of alkyl aromatics comprises contacting an alkyl aromatic feed material with a catalyst comprising a metal of Group VIB of the Periodic System deposited on a synthetic mordenite base. Further improvement of the catalyst is obtained by adding a Group -I, Group II, Group IV, a Rare Earth metal or mixtures thereof. Further improvements of the process are obtained by maintaining the temperature between about 700 and l,l F and the pressure between about 0 and 2,000 psig. Where toluene is the feed, additional para-xyleneis produced by isomerizing ortho-.- and meta-xylenes.

BRIEF DESCRIPTION OF THE DRAWINGS The drawing shows a flow .diagram ofa process system in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION Alkyl aromatic feed materials for use in accordance with the present invention can be any alkyl aromatic having at least one transferrable alkyl group. Primary materials are alkyl aromatics having from seven to l5 carbon atoms, mixtures of such alkyl aromatic hydrocarbons, or hydrocarbon fractions rich in such alkyl aromatic. hydrocarbons. Such feeds include mono-'anddi-aromatics, such asalkyl benzenes and alkyl naphthalenes.v Preferably, the alkyl group should contain no more than about four carbon atoms. A preferred feed in accordance with the, present invention is toluene. Accordingly, disproportionation of range, thermal demethylation occurs. The pressure utilized in accordance with the present invention has also been determined to be a critical factor. Accordingly, the process should be carried out between about 0 and 2,000 psig and preferably, between 300 and 600 psig. lthas been found that below the desired pressure range, conversion is low and the aromaticity of the product is high. On the other hand, at higher pressures, conversion is high, but liquid recoveries are low due to hydrogenation and hydrocracking. A liquid hourly space velocity between about 0.1 and 10, and preferably between 0.25 and L0, should be utilized and a hydrogen-to-hydrocarbon molev ratio between about 1 and 10 to l and preferably between 2 and 4 to l is desired.

The high severity conditions required to obtain disproportionation of alkyl aromatics, particularly the disproportionation of toluene, has been found to lead to catalyst deactivation clue to selective adsorption and condensation of aromatics on the catalyst surface and carbon laydown on the catalyst. It was found that the condensation and adsorption of aromatics on the catalyst is a temporary poison and that this condition can be alleviated by utilizing high hydrogen partial pressures. In addition, this temporary deactivation of the catalyst'can be overcome to completely rejuvenate the catalyst to near virgin activity by hydrogen-purging of the catalyst in the absence of aromatic hydrocarbon feed. While cokeor carbon deposition on the catalyst is a permanent poison, it has been found, in accordance with the present invention, that carbon laydown can be vention. Further, it was found that when these catalysts become deactivated by carbonlaydown, they can be restored to near virgin activity by regeneration in air.

The zeolites are a class of hydrated silicates of aluminum and either sodium or calcium or both, having the general formula Na OAl O SiO xH O. Originally, the term zeolite described a group of naturally-occuring minerals which were principally sodium or calcium aluminosilicates. Such naturally-occurring zeolites include for example, chabazite, gmelinite, erionite, faujasite, analcite, heulandite, natrolite, stilbite, thomsonite, etc. Synthetic zeolites are generally known in the trade by a tradename or trade designation applied by the specific manufacturer. For example, a synthetic mordenite is designated Zeolon by its manufacturer, the Norton Company. Zeolites generally have arigid, three-dimensional anionic network with intracrystallinechannels whose narrowest cross-sectionyhas essentially a uniform diameter. Thus, zeolites, of both natural and synthetic origin, can be distinguished from crystalline aluminosilicate clays,

' such as bentonite, which have a two-dimensional layer structure, and silica-alumina synthetic catalysts which are amorphous aluminosilicates having a random structure. I

Zeolites whose atoms are arranged in a crystal lattice in such a way that there are a large number of small cavities interconnected by smaller openings or pores of precisely uniform size are generally referred to as molecular sieves. Some natural zeolites exhibit molecular sieve characteristics to a limited degree. However, the synthetic zeolites as a class exhibit these charac teristics.

Synthetic mordenite, designated Zeolon by the Norton Company, has a highsilicon to aluminum ratio, generally about 5 to l. The postulated formula for this material is (Ca,N a A1 Si O 6H O. The basic unit is a tetrahedron consisting of one silicon or aluminum atom surrounded by four oxygens. The crystal is made up of 4 and S-membered rings of these tetrahedra. The chains are linked together to form a network having a system of large parallel channels interconnected by small cross channels. Such synthetic mordenite is also referred to as a Type Z molecular sieve.

The active Group VIB metal added to the mordenite base include chromium, molybdenum and tungsten, preferably in their oxide form and in amounts between about 1 and 20 percent by weight. I

It has also been found that conversion may be improved and, more significantly, carbon laydown on the catalyst may be reduced by the addition thereto of a promoter. Such promoters may be selected from Group I of the Periodic System, such as potassium, rubidium, cesium, etc., Group II of the Periodic System, such as calcium magnesium, strontium, etc., a Rare Earth metal of the Periodic System, such as cerium, thorium, etc, a Group IV metal of the Periodic System, such as tin or lead, or mixtures of these, and particularly mixtures of Group IV metal with one of the other groups mentioned. The promoters are preferably in their oxide form and are present in amounts of about 1 to 15 percent by weight based on the weight of the finished catalyst.

The following table shows a comparison of the catalyst of this invention with the same active metal deposited on a Type Y zeolite for the disproportionation of toluene.

TABLE I esend Yet-3L lt is to be observed from the above that selectivity is improved by the present catalyst. During the course of the run no activity decline was observed and greater yields were obtained at lower severities with only a slight loss in liquid recovery.

In accordance with the present invention, an integrated process for the production of benzene and para-xylene from toluene can be carried out with resultant high yields of these two valuable products. This process is best described by reference to the drawmg.

In accordance with the drawing, toluene is introduced to the system through line 10, hydrogen is added through line 12 and these materials are passed over the catalyst of the present invention in the disproportionation reactor 14. The effluent passing through line 16 is passed to a flash drum for the'removal of hydrogen and any light gases produced. These materials are discharged through line 18. Since little or no demethanation occurs, the hydrogen is substantially pure and may be recycled to the disproportionation reaction without further treatment. However, in some instances, further purification of the hydrogen is necessary before recycle or reuse. The liquid product passes through line 20 to a first distillation unit 22. In distillation unit 22, benzene is.recovered as an overhead through line 24. The bottoms product from distillation unit 22 passes through line 26 to a second distillation unit 28. In distillation unit 28, toluene is removed as an overhead product and recycled to the disproportionation section through line 30. The bottoms product from distillation unit 28 is a mixture of xylenes which is discharged through line 32. This product may be withdrawn, as such, through line 34. Preferably, however, the xylene product is-passed through line 36 to crystallization unit 38. In crystallization unit 38, paraxylene is selectively removed and withdrawn through line 40. The mother liquorfrom the crystallization section is passed through line 42 to an isomerization unit 44. Hydrogen is added through line 46. In the isomerization unit 44, the equilibrium concentration of parazylene is re-established and the material may then be recycled through line 48 to crystallization unit 38 for further para-xylene separation.

The isomerization reaction should be carried out under more mild conditions than the disproportionation. Catalysts useful in the disproportionation reaction might also be used in the isomerization or conventional v catalysts, such as, platinum on slicia-alumina, can be used. The isomerization may be carried out at temperatures of about 500 to 900 F, and preferably 550 to 650 F, pressures of 50 to 2,000 psig, and preferably 300 to 600 psig, at a liquid hourly space velocity of 0.1 to 10, and utilizing a hydrogen-to-hydrocarbon mole ratio between about 1 and 20 to 1.

When reference is made herein to the Periodic System of Elements, the particular groupings referred to are as set forth in the Periodic Chart of the Elements in The Merck Index, Seventh Edition, Merck & Co., Inc., 1960.

The term -alkyl 'transferof alkyl aromatics as used herein is meant to include disproportionation and transalkylation. Disproportionation, in turn, is meant to include conversion of two moles of a single aromatic, such as toluene, to one mole each of two different aromatics, such as xylenes and benzene. Transalkylation is meant to include conversion of one mole each of two different aromatics, such as xylenes and benzene, to

one mole of a single different aromatic such as toluene.

The alkyl transfer defined above is also to be distinguished from isomerization where there is no transfer of alkyl groups from one molecule to another but simply a shifting of ,alkyl group around the aromatic ring, such as isomerization of xylenes, or rupture of the ring or the alkyl side chain and rearrangement of splitoff carbon atoms on the same molecule. The alkyl transfer is also to be distinguished from a hydrogen transfer reaction, such as the hydrogenation of aromatics, the dehydrogenation of cycloparaffms and like reactions.

What is claimed is:

1. A process for the alkyl transfer of alkyl aromatics; comprising, contacting an alkyl aromatic feed material with a catalyst consisting essentially of l to 20 percent by weight of a Group VIB metal of the Periodic System deposited on a synthetic mordenite base, at a temperature of about 700-1,l00 F, a pressure of about 0 to 2,000 psig., a liquid hourly space velocity of about 0.1 tolO, and a hydrogen-to-hydrocarbon mol ratio between about 1 and 10 to l to cause alkyl transfer on said aromatics.

2. A process in accordance with claim 1 wherein the Group VIB metal is chromium.

3. A process in accordance with claim 1 wherein the Group VIB metal is molybdenum.

4. A process in accordance with claim 1 wherein the Group VIB metal is tungsten.

5. A process in accordance with claim 1 wherein the feed material contains substantial volumes of toluene.

6. A process in accordance with claim 5 wherein unconverted toluene is separated from the alkyl transfer product and said unconverted toluene is recycled to the disproportionation step.

7. A process in accordance with claim 5 wherein xylenes are separated from the alkyl transfer product and para-xylene is separated from said xylenes.

8. A process in accordance with claim 7 wherein the xylenes remaining after the separation of para-xylene are subjected to isomerization, at a temperature of about 500 to 900 F, a pressure of about 50 to 2,000

psig., a liquid hourly space velocity of about 0.1 to 10 and a hydrogen-to-hydrocarbon mol ratio between about 1 and 20 to 1 to produce additional para-xylene.

9. A process in accordance with claim 1 wherein the flow of feed material through the catalyst is interrupted periodically and the flow of hydrogen is continued for a time sufficient to reactivate the catalyst.

10. A process in accordance with claim 1 wherein the flow of feed material and hydrogen through the catalyst is discontinued and the catalyst is calcined in an inert atmosphere under conditions sufficient to reactivate the catalyst.

1 l. A process for the alkyl transfer of alkyl aromatics comprising contacting an alkyl aromatic feed material with a catalyst consisting essentially both of l to 20 per- 8 cent by weight of a Group VlB metal of the Periodic System and about 1 to 15 percent by weight of a metal selected from the group consisting of Group I, Group II, Group IV and the Rare Earth metals of the Periodic System and mixtures thereof deposited on a synthetic mordenite base, at a temperature of about l00-1,l00

F, a pressure of about 0 to 2,000 psig., a liquid hourly space velocity of about 0.1 to 10, and a hydrogen-tohydrocarbon mol ratio between aboutl and 10 to 1 to cause alkyl transfer on said aromatics.

Aug. 3 1988.

Disclaimer 3,699,'181.-R0nald A. Kmecalc, and Stephen M. lfo'vaciz, Ashland, K ALK- YL TRANSFER OF ALKYL AROMATIOS WITH GRO P VIB METALS ON MORDENITE. Patent dated Oct. 17, 1972. Disclaimer filed Dec. 20, 1971, by tli e's'ei'gnee, AshZa/nd Oil, Inc. Hereby disclaims the pe [Oficz'al Gazette M arch;

of the term of the patent subsequent to 

2. A process in accordance with claim 1 wherein the Group VIB metal is chromium.
 3. A process in accordance with claim 1 wherein the Group VIB metal is molybdenum.
 4. A process in accordance with claim 1 wherein the Group VIB metal is tungsten.
 5. A process in accordance with claim 1 wherein the feed material contains substantial volumes of toluene.
 6. A process in accordance with claim 5 wherein unconverted toluene is separated from the alkyl transfer product and said unconverted toluene is recycled to the disproportionation step.
 7. A process in accordance with claim 5 wherein xylenes are separated from the alkyl transfer product and para-xylene is separated from said xylenes.
 8. A process in accordance with claim 7 wherein the xylenes remaining after the separation of para-xylene are subjected to isomerization, at a temperature of about 500* to 900* F, a pressure of about 50 to 2,000 psig., a liquid hourly space velocity of about 0.1 to 10 and a hydrogen-to-hydrocarbon mol ratio between about 1 and 20 to 1 to produce additional para-xylene.
 9. A process in accordance with claim 1 wherein the flow of feed material through the catalyst is interrupted periodically and the flow of hydrogen is continued for a time sufficient to reactivate the catalyst.
 10. A process in accordance with claim 1 wherein the flow of feed material and hydrogen through the catalyst is discontinued and the catalyst is calcined in an inert atmosphere under conditions sufficient to reactivate the catalyst.
 11. A process for the alkyl transfer of alkyl aromatics comprising contacting an alkyl aromatic feed material with a catalyst consisting essentially both of 1 to 20 percent by weight of a Group VIB metal of the Periodic System and about 1 to 15 percent by weight of a metal selected from the group consisting of Group I, Group II, Group IV and the Rare Earth metals of the Periodic System and mixtures thereof deposited on a synthetic mordenite base, at a temperature of about 700*- 1,100* F, a pressure of about 0 to 2,000 psig., a liquid hourly space velocity of about 0.1 to 10, and a hydrogen-to-hydrocarbon mol ratio between about1 and 10 to 1 to cause alkyl transfer on said aromatics. 